How to use Pulses - US Dry Pea & Lentil Council > Home · 2016-08-30 · How to use pulses in...

How to use Pulses in Gluten-Free, Allergen-Averse Product Development

June 20, 2013

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How to use Pulses in Gluten-Free, Allergen-Averse Product Development

June 20, 2013

Funds for this project were provided through the Idaho State Department of Agriculture Specialty Crop Block Grant Program.

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! Overview: Pulses and pulse-based ingredients

! Overview: The gluten-free and allergen-averse market opportunity

! Principles in gluten-free formulation

! How to use pulses in gluten-free and allergen-averse formulations

! Conclusions

Presentation Objectives

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! Pulses – definitions and nomenclature

! Nutritional advantages of pulses

! Pulse production in the United States

Overview: Pulse and Pulse-Based Ingredients

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Section 1

1.  Pulses are legumes classified separately from oilseeds, such as peanuts and soybeans.

2.  There are 10 categories of pulses, as defined by the U.N. Food & Agriculture Organization (FAO). Of these, seven are of commercial importance as foods and only five are significant in international food trade. The remainder serve primarily as animal feeds.

3.  Because they return or “fix” nitrogen in the soil, pulses are highly sustainable and often used as rotational crops to restore the quality of farmland.

4.  Rich in protein, protein quality, soluble fiber, insoluble fiber, antioxidants, vitamins, minerals, and low in oil content, pulses are gaining attention as nutritionally superior foods and food ingredients.

5.  Pulses are used in many different ways in foods today. 6.  Pulses are also free of gluten and other allergens that must be declared

in FDA allergen declaration labels.

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What are Pulses?

Pulses important to human food consumption: 1.  Chickpeas (garbanzo beans)

2.  Dry beans (Phaseolus spp.)

3.  Lentils

4.  Dry peas (field peas)

5.  Broad (Fava) beans

6.  Pigeon peas

7.  Cowpeas

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What are Pulses?

Of these seven categories, only the first five are important to interna6onal trade. Cowpeas and pigeon peas are important food crops primarily in Africa and Asia, but are rarely traded across na6onal borders.

We will focus upon three categories produced in the United States:

! Chickpeas (garbanzo beans)

! Dry peas (field peas)

! Lentils

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What are Pulses?

Split Yellow Peas Whole Green Peas

Chickpeas (Garbanzo)

Red Lentils Pardina Lentils Regular Lentils

Pulses that are important to food formulation

There are mul6ple varie6es of peas and len6ls. The varie6es presented in this slide are the primary varie6es used in industrial food manufacture.

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Pulses offer Exceptional Nutritional Value PULSE&COMPOSITION

[&g/100g&]

Starch

Food&Reference Protein Fat &&Sugars Fiber

Beef1 77.5 8.6 0.0 0.0

Whole&Soy&Flour&H&Raw 35.0 20.0 25.6 9.6

Dry&Peas 23.7 1.3 45.5 16.6

Regular&LenRls 26.3 1.1 45.0 13.6

Chickpeas 24.4 5.9 41.1 8.7

Whole&Wheat 13.2 2.5 61.3 10.0

Whole&Rice&Flour 5.6 1.4 77.7 2.4

Tapioca&Flour 0.2 0.0 87.8 0.9

1 "Whole"Chuck,"10%"moisture"basis

Sources:"Canadian"Grain"Commission;"U.S."Dept."of"AgricultureCARS;"Cho,"S.,"Prosky,"L."and"Dreher,"M.""""""""""""""""Complex"Carbohydrates"in"Foods,"1999,"Marcel"Dekker,"Inc.,"New"York,"NY."

Plus…

!   Superior amino acid profile

!   Vitamins

!   Minerals

!   Low-Glycemic Index

!   Non-GMO

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What about Protein and Fiber? 2012 Food & Health Survey Consumer Attitudes Toward Food Safety, Nutrition & Health Survey conducted by the International Food Information Council (IFIC) The percentage of consumers surveyed that have considered whether or not a food contains the following nutrients when making purchase decisions about packed food and beverages is:

Protein and fiber are sought-after nutrients!

! Fiber 62%

! Protein 56%

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Where are Pulses Grown? The United States is one of the premier pulse-producing regions in the world.

Because of the U.S.’s highly developed quality grading, handling and production control systems, U.S. pulse producers receive top dollar for their pulses in world export markets.

The United States also provides… !   A superior production, manufacturing

and distribution infrastructure.

!   Multiple university and technical centers to provide technical support and innovation.

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Pulses as Food Ingredients Pulses can be processed into a variety of food ingredients.

! Dry peas

! Chickpeas

! Lentils

Flours

Pulse /Cereal Blends

Flakes

Pastes

Ingredients E

nzym

e In

activ

atio

n

Protein Concentrates

Starches

Fractions

Particulates

Specialty

Gluten-Free and Allergen-Averse Market Opportunities !   Size and dynamics of the

gluten-free / allergen-averse market

!   Why this market will continue to grow

!   The importance of nutritional parity.

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Section 2

Why Gluten-Free and Allergen-Averse Products?

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1.  CELIAC DISEASE: The primary driver for gluten-free products is celiac disease, which is estimated to affect 0.8% to 1.2% of the U.S. population.

2.  GLUTEN SENSITIVITY: However, this category also addresses the needs of people with gluten sensitivity and wheat allergies. Medical and nutritional literature estimates for the incidence of gluten sensitivity range from 0.5% to 7.0% of the population.

3.  OTHER FOOD ALLERGIES: In addition, many other consumers are concerned about consuming gluten-containing products or other potential allergens for a variety of other health-related reasons.

4.  OTHER (athletes, etc.)

GLUTEN-‐ and/or ALLERGEN-‐FREE is oHen a family decision. Households with members that suffer from celiac disease or other food allergies are more likely to remove all offending foods from their household.


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U.S. Food Allergen Labeling and Consumer Protection Act of 2004

! FALCPA required all foods to clearly identity all ingredients that contained one or more of the identified allergens.

! Pulses can play important roles as ingredient alternatives for those food allergens highlighted in red.

•  Milk •  Eggs •  Fish •  Crustacean shellfish •  Tree nuts •  Peanuts •  Wheat •  Soybeans

FALCPA passage was based on estimates that eight major food allergens account for 90% of all food allergies:

Not later than 4 years after the date of enactment of this Act, the Secretary shall issue a final rule to define, and permit use of, the term “gluten-free'' on the labeling of foods


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U.S. Food Allergen Labeling and Consumer Protection Act of 2004 The U.S. Food & Drug Administration is behind schedule in formulating final rules to govern “gluten-free” claims on foods.

SEC. 206. GLUTEN LABELING. Deadlines. Regulations. 21 USC 343 Not later than 2 years after the date of enactment of this Act, the Secretary of Health and Human Services, in consultation with appropriate experts and stakeholders, shall issue a proposed rule to define, and permit use of, the term ”gluten-free'' on the labeling of foods.


0.00

1.00

2.00

3.00

4.00

5.00

6.00

1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007

PER

CEN

T

YEAR

Percent of children with a reported food or digestive allergy in 12-month period

less-‐than 5 years 5-‐17 years

The incidence of food allergies in children has been trending upwards.

Adapted from : Branum A, Lukacs S. Food allergy among U.S. children: Trends in prevalence and hospitalizations. National Center for Health Statistics Data Brief. 2008. Retrieved from http://www.cdc.gov/nchs/data/databriefs/db10.htm

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Hospitalizations of children for food allergy-related problems have increased dramatically.

Adapted from : Branum A, Lukacs S. Food allergy among U.S. children: Trends in prevalence and hospitalizations. National Center for Health Statistics Data Brief. 2008. Retrieved from http://www.cdc.gov/nchs/data/databriefs/db10.htm

2,615

4,135

9,537

-‐

2,000

4,000

6,000

8,000

10,000

12,000

1998-‐2000 2001-‐2003 2004-‐2006

AVG

NU

MB

ER O

F D

ISC

HA

RG

ES P

ER Y

EAR

YEARS

Average Number of Hospital Discharges per Year children under 19 with food allergy-related diagnoses

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+ 58 %

+ 130 %

The U.S. Food & Drug Administration has variously indicated that… …“millions of Americans” suffer food allergy reactions every year, …leading to 30,000 hospitalizations …and 150 deaths per year.

Packaged Facts Report (October 2012) “The market for gluten-free foods and beverages has continued to grow even faster than anticipated, reaching $4.2 billion in 2012, for a compound annual growth rate of 28% over the 2008-2012 period.” “18% of adults are buying or consuming foods products tagged as gluten-free” “Packaged Facts projects that U.S. sales of gluten-free foods and beverages will exceed $6.6 billion by 2017.”

Packaged Facts Report projections are based on Food, Drug and Mass Merchandise (FDMx) product scan data.

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How Big is the Gluten-Free Market Opportunity?

SPINS /Mintel Gluten-Free Report (Sept, 2011) The “best case” projection was $10 billion in sales by 2013. August, 2012 update - $12.4 billion, "including Walmart”)

SPINS / Mintel gluten-free market projections are based on Food, Drug and Mass Merchandise (FDMx) product scan data PLUS natural food and specialty retailers.

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However, the following categories were not included in either the Packaged Facts or SPINS /Mintel gluten-free market surveys:

BEST VANTAGE Inc. estimates the current gluten- and allergen-free market size at $10 - 15 billion with a potential to reach $70 billion by 2020.

! Whole Foods (about 15% of all retail food and foodservice sales)

! Trade Joe’s ! Restaurant /food service ! Store brands ! PLU (coded-entry sales) ! Multilevel marketers ! Internet Sales.

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For comparison, total es6mated 2012 wholesale food retail and foodservice sales in the U.S. were about $1.3 trillion in 2012.

The Importance of Nutritional Parity

1.  Wheat flour is one of the most important venues of nutritional enrichment in the U.S. diet.

2.  By substituting for wheat flour, gluten-free /allergen-averse products risk making themselves vulnerable to claims of being nutritionally inferior to wheat flour-containing products.

3.  Pulses add important nutritional value to gluten-free/allergen-averse

products.

4.  We also recommend additional fortification and enrichment, as needed.

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Principles of Gluten-Free and Allergen-Averse Formulation !   Formulation of gluten-free foods

!   Achieving or exceeding nutritional parity

!   Gluten-free starting formulations

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Section 3

Formulation of Gluten-Free and Allergen-Averse Foods Major Food Allergens

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•  Milk •  Eggs •  Fish •  Crustacean shellfish •  Tree nuts •  Peanuts •  Wheat •  Soybeans

Major Food Ingredient Alternatives ! Pulse flours ! Rice flour ! Tapioca flour ! Quinoa ! Sorghum ! Potato flour ! Teff ! Sweet potato flour ! Corn ! Oat flour ! Pulse starches ! Pulse proteins ! Other proteins and starches

Food product developers have many ingredient alterna6ves available to them for use as subs6tutes for iden6fied food allergens.

Formulation of Gluten-Free and Allergen-Averse Foods

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Proteins and carbohydrates provide the two core building blocks in most food formulations:

•  Structure •  Strength •  Texture /mouthfeel •  Coloration •  Emulsification •  Gelation •  Film-forming •  Foaming

Protein Functionality

Carbohydrate* Functionality

* Starches, hydrocolloid gums, dietary fibers.

•  Water control •  Viscosity •  Flavor •  Opacity / turbidity •  Particle suspension •  Adhesion •  Agglomeration

•  Structure •  Strength •  Texture /mouthfeel •  Emulsification •  Gelation •  Film-forming •  Foaming

•  Water control •  Viscosity •  Opacity / turbidity •  Particle suspension •  Adhesion •  Agglomeration Both food protein and carbohydrate

components contribute a wide selec6on of func6onal proper6es to foods.

People Pay Premium Prices for Gluten-Free!

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$-‐

$0.20

$0.40

$0.60

$0.80

$1.00

$1.20

Rolls & Buns

Bread Pasta Crackers

$-Pr

ice

/ oz.

Gluten-Free Price Premiums Conventional Gluten-Free

+ 251 %

+ 227 %

Based on random retail store checks conducted by BEST VANTAGE Inc. in the Chicago metropolitan area during May 2013.

+ 141 %

+ 97 %

The good news is that, for now, people are willing to pay s6ff premiums for gluten-‐free foods, which gives food product developers considerable flexibility in their choice of ingredients.

Pea, chickpea and len6l ingredients tend to be very cost-‐compe66ve with other gluten-‐free ingredient alterna6ves.

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Plus… !   Superior amino

acid profile

!   Vitamins

!   Minerals

!   Low Glycemic Index

!   Non-GMO

Pulses contain high-‐levels of proteins, soluble and insoluble dietary fibers and starches (including resistant starches) that combine together in many unique ways that define their func6onal proper6es in food products.


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Suppliers of pea, chickpea and lentil-based ingredients offer a wide range of highly specific protein and starch ingredients for use in food formulations.

Available Pulse Ingredients List of Pulse Ingredient Suppliers •  Whole pulses

•  Roasted pulses •  Flakes, grits •  Raw flour •  Air-classified flours •  Pre-cooked flour •  Pre-gelled flour •  Protein concentrates •  Protein isolates •  Starches •  Bran meal •  Fiber

George F. Brocke & Sons Kendrick, ID

Harvest Innovations Indianola, IA

Inland Empire Foods, Inc. Riverside, CA SK Food International Fargo, ND

Woodland Foods, Inc. Gurnee, IL

United Pulse Trading Bismarck, ND

Hinrichs Trading Co. Pullman, WA

Dakota Dry Bean, Inc. Grand Forks, ND Fiberich Technologies, Inc. St. Louis Park, MN


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OBJECTIVE: To duplicate the functional properties of wheat flour in a food system

•  Proteins •  Starches •  Shortenings •  Leavening agents •  Emulsifiers •  Water •  Flavoring •  Salt

Pulse flours and other gluten-free flours offer a range of functional protein combinations.

Protein functionality can be enhanced using pulse flour fractions (e.g., pea protein concentrates and isolates) and/or film-forming hydrocolloids, such as xanthan gum.

Proteins Baked Goods Ingredients


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Texturizers Baked Goods Ingredients Dough and finished product textures can be further optimized using combinations of gums, shortenings, enzymes and emulsifiers.

Water: the most important texturizing ingredient is water.

Minerals (e.g. calcium) can affect product functionality and texture.


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Flavor Systems

Baked Goods Ingredients

Salt, acidulants and flavors can remain largely unchanged, but ensure that they do not contain allergens as carriers.

A choice between chemical and yeast leavenings will significantly affect flavor.

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1.  Wheat flour is an important dietary source of micronutrient enrichment.

2.  In the interest of nutritional parity, we submit that it is important to equal or exceed the micronutrient content contributed by enriched wheat flour.

3.  We recommend adding a vitamin-mineral premix to achieve or exceed nutritional parity.

•  Optimize your vitamin-mineral blend dilution

to a practical working level using carriers.

•  Confirm that your vitamin-mineral carrier is gluten-free.

Courtesy of The Wright Group, Inc.

Vitamin-‐Mineral Premix • Niacin •  Iron •  Thiamine

•  Riboflavin •  Folic Acid

The Importance of Nutritional Parity

The Importance of Nutritional Equivalence

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•  Increased protein from 1g to 2g per 30g serving.

•  Increased Total Dietary Fiber from 0g to 2g per 30g serving.

Gluten-Free Shortbread

Replacement of 30% of a gluten-free blend of tapioca and rice flours with lentil flour resulted in:

INGREDIENTS: Gluten-Free Flour (tapioca flour, rice flour), Sugar, Butter, Lentils, Eggs, Salt, Baking Soda, Flavor, Xanthan Gum.

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•  21g Protein per serving

Gluten-Free Organic Lentil Pasta Serving size: 85g

%-‐Formula 24.7%

15.3%

•  Riboflavin 15% •  Calcium 20% •  Vitamin B6 10% •  Iron 40% •  Thiamin 20% •  Niacin 8% •  Folate 30% •  Zinc 25%

Percent Daily Value

•  13g Total Dietary Fiber per serving

The Importance of Nutritional Equivalence

The nutri6onal enhancement contributed by pulses is evident in this pasta formula6on, both in terms of macro-‐ and micronutrients.

Gluten-Free and Allergen-Averse Formulations

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Gluten-Free Pasta

•  Pasta is one of the easiest products to render gluten-free.

•  The challenge is to obtain a consistent and appealing al dente texture that is robust to variations in cooking and preparation conditions.

•  Pulses can comprise from 0% to 100%

of a gluten-free pasta formula.

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Gluten-Free Pasta

Examples of gluten-free pasta ingredient statements:

[INGREDIENTS: Corn Flour; Rice Flour, Mono & Diglycerides]

[INGREDIENTS: Organic Rice Flour; Organic Rice Starch; Organic Potato Starch; Organic Soy Flour]

[INGREDIENTS: Rice Flour; Rice Bran Extract]

[INGREDIENTS: Lentils; Water]

Pasta textures can be further enhanced by using purified pulse starches and proteins, as well as hydrocolloids, such as xanthan or guar.


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Gluten-Free Pasta

Source: Northern Crops ins1tute

Effect of pea flour on pasta quality

100% Legume Pasta

Pasta al dente quality and robustness increased with increased levels of pea flour incorpora6on.

Rice: Quinoa 75% : 25%

Chickpea 100%

Yellow Pea 100%

Corn 100%

Level of pea flour incorporaUon


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Chocolate-Chip Cookies Laboratory-scale formulation

Note: although this formula contains eggs, suitable egg replacers are available as alternatives.

•  Cream butter and sugar, add eggs and vanilla.

•  Gradually add dry ingredients to creamed mix.

•  Mix 1-minute at medium speed. •  Stir in chocolate chips •  Spoon and bake 8 – 10 min. @ 375oF

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Gluten-Free Pizza-Crust Laboratory-scale formulation

•  Mix instant yeast into warm water. •  Combine dry ingredients in mixer. •  Slowly add yeast/water blend and oil into mixer under medium-to-low shear until thoroughly blended. •  Roll dough into desired shape, use tapioca flour to prevent sticking. •  Bake 10-min. @ 400oF (204oC). •  Add toppings and finish bake.


Weight (g) Formula-%

Chickpea flour 300 29.9%Sugar 20 2.0%Tapioca flour 150 14.9%xanthan gum 20 2.0%Salt 4 0.4%Italian Seasoning 10 1.0%Instant Yeast 30 3.0%Water (100oF / 38oC) 460 45.8%Canola oil 10 1.0%


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Other Gluten-Free, Allergen-Averse Applications Pea, chickpea and lentil flours and fractions can enhance a wide range of gluten-free, allergen-averse food applications, such as: •  Soups and sauces (thickeners, emulsifiers) •  Dips and spreads (thickeners, emulsifiers) •  Liquid meals (thickeners, protein source) •  Fried foods (batters, breadings) •  Meatloaf and meatballs (binders, moisturizers) •  Trail mixes •  Nutrition bars •  Extruded snacks

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REMINDER Please email WEBINAR questions to [email protected]

Summary and Conclusions !   Summary & Conclusions

!   Additional Resources

!   Questions and Answers

Section 4

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Summary and Conclusions !   Gluten-free, allergen-averse foods represent a fast-growing market based

on legitimate consumer concerns. It is here to stay.

!   Peas, chickpeas and lentils are highly sustainable agricultural crops produced in the United States to the highest global quality standards.

!   Pulses contain no allergens that must be declared on food package labels.

!   Nutritional parity with wheat flour is important to the long-term success of gluten-free, allergen-averse foods.

!   Dry peas, lentils and chickpeas provide cost-effective functional ingredients for gluten-free and allergen-averse food product development that are:

a.  High in protein b.  High in Total Dietary Fiber c.  Low in fat d.  Rich in essential vitamins and minerals e.  Low Glycemic Index f.  Non-GMO

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Additional Resources !   The USA Dry Pea and Lentil Council

Contact: Ali McDaniel Email: [email protected] Tel. 1-208-596-5026 Website: www.pea-lentil.com

!   Northern Crops Institute (North Dakota State University) Contact: Thunyaporn “Naggie” Jeradechachai Email: [email protected] Tel. 1-701-231-7736

Website: www.northern-crops.com !   BEST VANTAGE Inc.

Contact: Daniel Best Email: [email protected] Tel. 1-847-714-9527 Website: www.bestvantageinc.com

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Industry Resources

Dakota Dry Bean, Inc. Grand Forks, ND

Fiberich Technologies, Inc. St. Louis Park, MN

George F. Brocke & Sons Kendrick, ID

Harvest Innovations Indianola, IA

Hinrichs Trading Co. Pullman, WA

Inland Empire Foods, Inc. Riverside, CA

SK Food International Fargo, ND

United Pulse Trading Bismarck, ND

Woodland Foods, Inc. Gurnee, IL

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A downloadable copy of this Webinar presentation will be posted on the USA Dry Pea & Lentil Council website in the near future @ www.pea-lentil.com. We will send webinar registrants an email notification when it becomes available.

Upcoming Webinars: Please stay tuned for future 2013 webinar presentations on more specific uses of pulse ingredients in food product development.

Additional Resources

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QUESTIONS?

REMINDER Please email WEBINAR questions to [email protected]


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Thank You for you participation

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How to use Pulses - US Dry Pea & Lentil Council > Home · 2016-08-30 · How to use pulses in...

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